Dispenser packaging

ABSTRACT

A packaging system for unit dispensing a predefined number of dosages or items at a time (or a predefined amount of liquid or flowable material, such as powder, lotions, or the like) is provided which integrates into a single form the materials, properties, and benefits of carton-based and foil blister-based packaging. The use of secondary processes such as the alignment of perforations between the carton material and foil blister, adhesion of foil blisters to carton surfaces, and adhesive-backed labeling allows the invention to be easily separated by the end-user into compact units whose portability facilitates and encourages adherence to dosage requirements. These features allow the user to remove a dosage from the packaging yet keep intact the physicality and functionality of the combined components.

CROSS-REFERENCE

[0001] This application claims the benefit of U.S. Provisional Application No. 60/403,695, filed Aug. 14, 2002, which application is incorporated herein, in its entirety, by reference thereto.

FIELD OF THE INVENTION

[0002] The present invention relates to the field of dispensers and packaging. More particularly, the present invention relates to unit-dosage dispensing of items utilizing foil blister based packaging integrated with the economy, convenience, and visual communication of a carton-based packaging solution. Such items to be dispensed via the dispensing packaging system include medicines such as pills, tablets, pellets, caplets, capsules; food items such as candy, nuts, gum, flavor packets, or other edible small items; vitamins; pet foods; hardware items such as screws, bolts, nuts or the like; office supply items; even liquids and flowable substances such as powders, lotions, cosmetics, topical solutions, or other physical items in which it is desired to limit the amount dispensed per each act of dispensation combined with the advantages of both foil blister and carton-based packaging.

BACKGROUND OF THE INVENTION

[0003] Two commonly used materials in the packaging of pharmaceutical products are carton (i.e., SBS board or other suitable material) and foil blister. Carton-based packaging provides a structurally sound surface area for the communication of user information (i.e., dosage, indications for use, precautions, and other FDA-mandated information) and product identity (manufacturer and product name, branding). Foil-blister packaging provides the product with protection from ambient conditions and the convenience and safety of unit-dispensing.

[0004] Standard unit-dosage packaging solutions typically consist of sheets of foil blister placed inside of a carton. The two separable components each provide unique functionality. The foil blister divides and protects (from environmental factors) the medication while the carton provides visual communication, transport, and storage. Such packaging solutions are almost always designed in such as way such that the carton provides the housing for the sheets of foil blisters, and the instructions for dosage and use; while the sheet of foil blisters contain multiple dosages of the medication according simply to the dimensions of the carton rather than the proper dosage. For example, a 3 inch by 4 inch sheet may contain twelve pills, while the proper dosage may be two pills per day.

[0005] Typically, the user reads the instructions and views other visual information on the outside of the carton, opens one end of the carton to withdraw one sheet of foil blisters containing multiple doses, and then must know the proper number of blisters/doses to separate and remove. After ingesting the dosage, the remainder of the sheet of foil blisters is then reinserted into the carton. This is generally true whether the medication is in pill form, tablet form, capsule form, caplet form or any other currently popular shape or delivery design that the medication is formed in.

[0006] Since there is no effective control mechanism to positively dispense only the needed amount of medication, there is the danger that the user will not separate the correct number of pills for the current dosage.

[0007] In addition the excess pills must then be returned to the carton. This repetitive act of dispensing and returning pills that are not needed for the current dose not only increases the possibility of damaging the foil blisters and thus the medication as it is returned to the carton, but the necessity of such is inconvenient, aggravating and also increases the chances of losing a portion of the medication. With the ever increasing costs of medication, better dispensing mechanisms are needed to ensure that a patient can dispense accurately only the amount of medication that is needed for the current dose.

[0008] A convenient packaging system that positively indicates the correct number of pills, tablets, etc. to take for the current dosage would have the further benefit that a sight challenged patient who could not read the instructions on the carton could rely on the number of pills that are needed based off the packaging system.

[0009] Furthermore, the end-user typically may not want to carry the entire carton of medication and instead desire to carry just the dosage needed while outside of the home. In such cases, it is desirable to combine the structural protection aspects of the carton for transport and housing with the safety and convenience of unit-dosage foil blisters. Carrying just an individual foil blister dosage has disadvantages such as the instructions for use are separated from the medication. In addition, it will be advantageous to have an integrated carton/foil blister system for individual samples of medications and other products such as cosmetics to be given to clients and potential customers.

[0010] Similar problems exist with regard to certain candies, gum, and the like which are sold in a carton of individual pieces of foil blister sheets in which an item which is dispensed when it is desired to be eaten. Likewise, a set of hardware items or household or medical disposables such as cotton swabs and the like are packaged in units within a carton and then end users must replace those remaining items which were not intended to be dispensed. Similar situations are presented across many fields, where a plurality of items are stored in carton packaging, but do not have an effective dispensation mechanism to accurately control dispensation of only the number of those items needed by the user at any particular time.

[0011] Other systems for dispensing medication according to dosage typically are of a more complex nature, are not meant to be disposable packaging, or are composed of materials such as plastic which are more expensive, heavier, and difficult to include visual communication such as printed instructions. For example, end-users may utilize a plastic container with 7 compartments for each day's medication, but most manually prepare the dosages and place into each compartment. Instructions are typically not printed on such plastic containers. Manufacturers or pharmaceutical companies or pharmacists do not wish to incur the cost, labor, or waste of providing such non-disposable systems.

[0012] Existing systems have a number of inherent drawbacks in the disclosed designs, whether being overly difficult to operate, overcomplicated making them unnecessarily expensive and not practical for universal use; or restricted for only one style or size of compartment or pill; costly or labor intensive to prepare, or do not combine visual and printed information with the correct dose.

[0013] In general, there is a need to provide a packaging system that is less expensive to manufacture and/or assemble, is easy to use, and which integrates the advantages of carton packaging with individual foil blister wrapped medications.

SUMMARY OF THE INVENTION

[0014] A unit-dosage item dispensing carton based packaging system for controllably dispensing a predefined number of items at a time (or a predefined amount of liquid or flowable material, such as powder, lotions, or the like) is provided which integrates into a single form the materials, properties, and benefits of both carton (or similar packaging) and foil blister-based (or similar) packaging. The use of secondary processes such as the alignment of perforations between the carton material and foil blister, use of perforations on internal and external surfaces for intuitive use, adhesion of foil blisters to carton surfaces, and adhesive-backed labeling allows the invention to be easily separated by the end-user into compact units whose portability facilitates and encourages adherence to dosage requirements. These features allow the user to remove a dosage from the packaging yet keep intact the physicality and functionality of the combined components.

[0015] However, the continued integration of the two materials and processes in these units ensure that the aforementioned advantages present themselves throughout the entire user experience. Greater convenience is achieved by combining the functionality of each component. The end-user will receive his or her medication in a one-piece enclosed carton that communicates usage information. Yet, he or she will then be able to easily and safely identify, remove, carry, and use the dosage he or she needs at that period of time.

[0016] The invention may be manufactured using SBS board or other suitable material. The material may be cut in patterns, such as the one shown in FIG. 1a, such that the carton, when folded, forms a three dimensional container configured to contain the medication.

[0017] Standard carton manufacturing processes may be used to assemble the carton. These processes include the insertion of a series of perforations, such as the perforations indicated across the lid in FIG. 1b, such that the pattern of perforations match the perforations of the foil blister packs to be adhered in the latter part of the process.

[0018] Before sealing the lid on the top of the carton, the medication itself may be pre-packaged in perforated foil blister and then lightly adhered to the underside of the lid (see FIG. 1c) utilizing standard manufacturing processes, for example. As mentioned above, the perforated pattern of the foil blister matches the perforation pattern of the carton. The edge of the lid may then be sealed to the front surface of the carton (see FIG. 1d).

[0019] Prior to assembly, graphics may be printed on one or more outer surfaces of the material. The graphics may be used to communicate information to both the distributors and end-users of the medication. This information may include, but is not limited to, branding of the medication and its manufacturer, general information (medication name, lot number, expiration date, and dosage), and specific information (medication ingredients, warnings, and directions).

[0020] Additionally or alternatively, a label with an adhesive-backing may be printed at the site of packaging. The label may contain information such as intended dates and/or times of medication usage or highlighted warnings. This label may be adhered to the front surface of the assembled carton's lid (see FIG. 1e) such that each separate dosage or tab is individually labeled. The label may likewise be perforated to match the pattern of the carton.

[0021] The perforations inserted during the assembly process are used to divide the packaged medication into tabs or dosages. For example, six perforated lines may be inserted to divide the medication into seven daily doses. The end-user can look at the graphics printed on either the label or the carton itself to identify the dosage to be taken that day. By pulling the tab (on the front surface of the lid) associated with the dosage, this allows the user to remove that dosage from the carton (see FIG. 2a, b). The perforations cut prior to use into the carton, with matching perforations cut into the foil blister, allow for easy and convenient separation of an individual integrated tab, of carton adhered to foil blister, from the remainder of the carton.

[0022] The dosage can then be placed in a purse, suitcase, or other bag for later use; the remaining medication can be left behind. In this way, at the time of the next recommended dosage, the user has ready access to the medication and can remove the foil blister containing the medication from the carton-based tab (see FIG. 2c). The foil itself is then peeled away, allowing the end-user to access the dosage (see FIG. 2d).

[0023] Preferred examples of the present invention are configured to dispense seven daily doses of two pills or items at a time. However, the number of daily doses held by a container, as well as the number of items dispensed at a time can be altered while still adhering to the advantages of the invention as described herein, as would be readily apparent to one of ordinary skill in the art upon reading the present disclosure.

[0024] The overall size of the carton as well as the shape of the carton can be modified. For example, in addition to the rectangular container, the carton can be shaped to form a cylindrical container, a square box container, or other irregular shapes.

[0025] In addition, any aspect of the perforations can be varied, such as the number of perforations, the spacing between the perforations, and the number surfaces such as top and bottom and sides which are perforated. The pattern and shapes of the perforations can be varied, for example a non-linear pattern to match the round shape of a round shaped tablet and matching foil blister pack. Further, other methods of facilitating separation may be utilized such as scoring.

[0026] Further, the integration of carton and foil blister can be varied and modified to provide similar advantages of the integration. Other packaging systems and enclosures in addition to foil blisters can be integrated with the carton. Other materials in addition to carton, such as flexible lightweight plastics, can be integrated with foil blister.

[0027] For example, variations include, but are not limited to, a carton with a smaller size and three perforations that divide the medication into three doses for different times of one day such as that configured in FIGS. 3a-3 b. The perforations may be placed on any of the surfaces, such as both the lid and bottom surfaces of the carton. Such patterns would maximize utilization of the internal volume of the carton. Because of the smaller overall size of this carton, there may be insufficient space on the outer surface. Information may also, or alternatively, be printed onto a paper insert, folded in a tri-fold manner to form a “w” shape when viewed laterally, and then placed inside of the carton.

[0028] These and other advantages and features of the invention will become apparent to those persons skilled in the art upon reading the details of the invention as more fully described below.

BRIEF DESCRIPTION OF THE DRAWINGS

[0029]FIG. 1A is a top down view of an example of a carton cutting pattern prior to assembly according to the present invention.

[0030]FIG. 1B is a view of the device of FIG. 1 shown with perforations to aid in future separation of individual tabs in a pattern to create individual tabs.

[0031]FIG. 1C shows the foil blister pack with a perforation pattern matching the carton, about to be adhered to one of the surfaces of the carton.

[0032]FIG. 1D illustrates the lid of the carton enclosing the medications with the carton container.

[0033]FIG. 1E illustrates the carton with the adhesive label attached to the front.

[0034]FIG. 2A illustrates one unit-dose tab in the process of removal tearing along perforations.

[0035]FIG. 2B illustrates one unit-dose tab removed from the main container with an integrated carton and foil blister.

[0036]FIG. 2C illustrates the separation of the carton tab from the foil blister.

[0037]FIG. 2D illustrates standard foil blister with foil removed from single tablet or capsule for removal and ingestion.

[0038]FIGS. 3A and 3B show an example of an alternative pattern and design for a smaller carton containing three times a day dosage with three total tablets.

DETAILED DESCRIPTION OF THE INVENTION

[0039] Before the present dispensing packing system and methods are described, it is to be understood that this invention is not limited to particular configurations, materials or items described, as such may, of course, vary. It is also to be understood that the terminology used herein is for the purpose of describing particular embodiments only, and is not intended to be limiting, since the scope of the present invention will be limited only by the appended claims.

[0040] Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. Although any methods and materials similar or equivalent to those described herein can be used in the practice or testing of the present invention, the preferred methods and materials are now described. All publications mentioned herein are incorporated herein by reference to disclose and describe the methods and/or materials in connection with which the publications are cited.

[0041] It must be noted that as used herein and in the appended claims, the singular forms “a”, “and”, and “the” include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to “a perforation” or “a unit tab dosage” includes a plurality of such perforations and unit tab dosages, and reference to “the surface” includes reference to one or more surfaces and equivalents thereof known to those skilled in the art, and so forth.

[0042] The publications discussed herein are provided solely for their disclosure prior to the filing date of the present application. Nothing herein is to be construed as an admission that the present invention is not entitled to antedate such publication by virtue of prior invention. Further, the dates of publication provided may be different from the actual publication dates which may need to be independently confirmed.

[0043] The present invention provides dispensing packaging methodology for simply integrating advantages of carton with foil blister for advantageous dispensing of unit dosages for a predefined number of small items. The example mechanisms are designed for release of one or two items at a time, although they may be designed, for example, to release three or more items at a time. Here forward, reference to an “item” is used not only to refer to a solid item of predefined size, shape and volume, but also to a predefined volume of liquid or other flowable material, such as powder, lotions, topical solutions, pellets and the like. The mechanisms described are designed to be utilized with existing packaging and manufacturing systems and processes, so that they are more universally applicable to a wide variety of products. Alternatively, the mechanisms described may be manufactured in their own packaging and later filled by a product (item) manufacturer.

[0044] Although described herein primarily with reference to medical items such as capsules, caplets and the like, the present invention is useful for dispensation of a wide variety of small items such as hardware items (e.g., screws, bolts, etc.), candies and gums, office supplies (e.g., paper clips, tacks, etc.), nuts or other food or cooking items, other small physical items that typically come packaged in a container having a plurality of such items, only one or a portion of which are generally desired to be dispensed by a user at any one time, and even liquids and flowable substances such as powders, lotions, and topical solutions.

[0045] Referring now to FIG. 1A, a top down view of an example of a carton based material which has been cut to a pattern 100 which will form the dispensing packaging according to the present invention is shown. In the example shown, flaps 120 are provided to be folded into a carton container 110, which in this case is standard rectangular box in shape. However, as noted above, the dispensing packaging may be manufactured in alternative sizes and shapes such as square, cylindrical, irregular, and other shapes. Alternative patterns in use by the packaging industry may be utilized to construct the container and additional patterns could be devised and would be readily apparent to those of ordinary skill in the art. In the instant example, the pattern provides for eight flaps 120 which when folded at 90 degree angles may be adhered utilizing standard manufacturing processes (e.g., heat bonding, adhesives, threads, or other know fixation techniques) and would be readily apparent to those of ordinary skill in the art. Another sample pattern is discussed below with FIGS. 3a to 3 c.

[0046] The carton container 110 may be manufactured using SBS board or other suitable material. For use with pharmaceuticals or food products, carton material 100 and foil blister 200 should be made from food grade, FDA approved materials. However, in general, the components of the present invention may be manufactured from a variety of materials, including high volume manufacturing materials, such as, but not limited to paper, plastics, thermoplastics, metals, etc. Further, the integration of carton and foil blister can be varied and modified to provide similar advantages of the integration. Other packaging systems and enclosures in addition to foil blisters can be integrated with the carton. Other materials in addition to carton, such as flexible lightweight plastics, can be integrated with foil blister.

[0047] Prior to assembly, graphics may be printed on the outer surfaces of the material 100. The graphics may be used to communicate information to both the distributors and end-users of the medication. This information may include, but is not limited to, branding of the medication and its manufacturer, general information (medication name, lot number, expiration date, and dosage), and specific information (medication ingredients, warnings, and directions).

[0048] Referring now to FIG. 1B, the perforations 130 may be cut, utilizing standard manufacturing processes readily apparent to those of ordinary skill in the art, into surface 140 which will form the lid 160 of the container 110. The perforations 130 inserted during the assembly process are used to divide the packaged medication into tabs 170. For example, six perforated lines 130 may be inserted to divide the medication into seven tabs 170 corresponding to daily doses. The perforations 150 cut prior to use into the carton, with matching perforations 250 cut into the foil blister 200, allow for easy and convenient separation of an individual integrated tab 300, of carton adhered to foil blister, from the remainder of the carton container 110. However, the present invention is not limited to the illustrated perforation 150 pattern. Any aspect of the perforations 150 can be varied, such as the number of perforations 150, the spacing between the perforations 150, and the number surfaces such as top and bottom and sides which are perforated. The pattern and shapes of the perforations 150 can be varied, for example a non-linear pattern to match the round shape of a round shaped tablet and matching foil blister pack 200, or a pattern of intersecting perforations 150. In addition, the pattern of perforations 150 may be alternatively cut the full length or partial length of a fold or section such that individual tabs 170 may be lifted, but not separated from the container 100 into a separate individual tab 300. Further, the facilitation of separation may be accomplished through other processes such as scoring.

[0049] The end-user can look at the graphics printed on either the label or the carton itself to identify the dosage to be taken that day. The user can pull the tab (on the front surface of the lid) associated with the dosage and remove that dosage from the carton (see FIG. 2a, b).

[0050] Referring now to FIG. 1c, eight flaps 120 are folded at 90 degree angles to and adhered utilizing standard manufacturing processes to form carton container 110 shown displayed with lid 160 open. Before sealing the lid 160 on the top of the carton container 110, the medication 202 may be pre-packaged in foil blister 200 and then lightly adhered to the underside of the lid (see FIG. 1c) utilizing standard manufacturing processes. FIG. 1c illustrates a method of matching the pattern of perforations 130 in the lid 160 with the pattern of the perforations 250 of the foil blister packs 200 to be adhered. The process and order of adhering the foil blister pack 200 to the lid 160 after the folding of flaps 120 may be varied according to manufacturing needs and efficiency, for example such that the adhering may precede the folding.

[0051] In FIG. 1d, the flap 170 of the lid 160 may next be adhered to the front surface 111 of the carton 110. In FIG. 1e, an adhesive label 180 is affixed to the flap 170, which may contain visual information. This information may include, but is not limited to, branding, and instructions such as the day or date and time for the dosage to be taken, and highlight warnings. Such adhesive label 180 may be perforated to align with the perforation pattern 150 to assist in the visual clues and physical ease of separation of individual tab 170 into individual integrated tab 300. However the present invention is not limited to placement of the adhesive label 180 to the flap 170, and such adhesive label 180 may be placed in any such position as provides the user with patient specific information that is not provided at the time of manufacture of the packaging.

[0052] After assembly of the invention, FIG. 2a illustrates the user peeling back the first individual tab 170 from the main carton container 110, revealing an individual foil blister pack 210 containing the capsules 202.

[0053] In FIG. 2b, the integrated dosage 300, consisting of foil blister pack 210 containing capsules 202 adhered to individual tab 170, has been separated form the main carton container 110. The dosage can then be placed in a purse, suitcase, or other bag for later use; the remaining medication can be left behind.

[0054] In FIG. 2c, the user has separated the individual carton tab 170 from the foil blister pack 210. The individual tab 170 may contain visual and textual information regarding the dose on either side of the tab.

[0055] In FIG. 2d, the individual tab 170 has been set aside and the user peels back the foil 211 from the foil blister pack 210 to release the capsule 202 from the sealed blister compartment 212, in order to now ingest the dosage.

[0056] For example, variations of the invention include, but are not limited to, a carton with a smaller size and three perforations that divide the medication into three doses for different times of one day such as that configured in FIGS. 3a-3 b. The perforations may be placed on any of the surfaces, such as both the lid and bottom surfaces of the carton. Such patterns would maximize utilization of the internal volume of the carton. Because of the smaller overall size of this carton, there may be insufficient space on the outer surface. Information may be additionally or alternatively printed onto a paper insert 400, folded in a tri-fold manner to form a “w” shape when viewed laterally, and then placed inside of the carton 110.

[0057] It is also to be noted that the alternatives described in FIGS. 3a and 3 b are non-limiting. This alternative design demonstrates the advantages of integrating multiple doses of medications that may be related. Such advantages can be applied to such situations as the need for drug “cocktails” where a combination of drugs is utilized, or simply multiple daily vitamins taken at specialized times during the day.

[0058] In addition, the methodology can be applied to cut a pattern into foil blister pack sheets alone such that the advantages of the invention may still be obtained. For example, the foil blister sheet rather than the carton may be cut into the pattern 100. In this instance, capsules 202 may be placed only on the perforated pattern area 130, which later forms the lid 160. The step of adhering the foil blister pack 200 to carton container 110 in this example, is not required.

[0059] This invention's integration into a single form with materials, properties, and benefits of carton and foil blister-based packaging presents advantages over other systems. The use of secondary processes such as the alignment of perforations between the carton material and foil blister, adhesion of foil blisters to carton surfaces, and adhesive-backed labeling allows the invention to be easily separated by the end-user into compact units whose portability facilitates and encourages adherence to dosage requirements. These features allow the user to remove a dosage from the packaging yet keep intact the physicality and functionality of the combined components. The continued integration of the two materials and processes in these units ensure that the aforementioned advantages present themselves throughout the entire user experience. Greater convenience is achieved by combining the functionality of each component. The end-user will receive his or her medication in a one-piece enclosed carton that communicates usage information. Yet, he or she will then be able to easily and safely identify, remove, carry, and use the dosage he or she needs at that period of time. Manufacturers can obtain these advantages for its customers, end users, and consumers, utilizing high volume, low cost, disposable materials.

[0060] A notable characteristic of this invention is the use and presence of aligned perforations on both the outer carton and inner foil layers. Perforations have been utilized in the manufacturing and distribution of numerous objects, including, but not limited to: carton-based packaging, documentation media, etc. This use of perforations have not only physically facilitated the easy separation of objects, they have also evolved into a visual communication element that signifies the ability of an object to be separated. The extension of the use of perforations to the outside carton layer provides an interface for the separation and use of product by the end user that is more intuitive than conventional packaging in which only the inner foil blister layer is perforated.

[0061] While the present invention has been described with reference to the specific embodiments thereof, it should be understood by those skilled in the art that various changes may be made and equivalents may be substituted without departing from the true spirit and scope of the invention. In addition, many modifications may be made to adapt a particular situation, material, composition of matter, process, process step or steps, to the objective, spirit and scope of the present invention. All such modifications are intended to be within the scope of the claims appended hereto. 

That which is claimed is:
 1. An item dispensing packaging device integrating the advantages of carton-based and foil blister-based packaging, for dispensing a predefined number of small items or a predefined volume of a substance at a time, said device comprising: a carton-based or similar material cut into a pattern to form a container and printed with text and image visual information; a pattern of perforations, or scoring or similar method of facilitating separation, cut into the carton to form a predetermined number of individual tab units which can be individually separated from the primary container; a foil blister based or similar packaging sheet cut with a pattern of perforations, or scoring or similar method of facilitating separation, matched to the pattern of perforations cut into the carton and a predetermined number of items between each perforation; and adherence of the foil blister pack to the carton container such that an integrated individual tab may be separated from the primary container for a single unit-dosage.
 2. The device of claim 1, wherein the predefined number of items is one or higher and wherein said predetermined number of tabs is seven.
 3. The device of claim 1, wherein said pattern is adjustable.
 4. The device of claim 1, wherein said foil blister pack is configured to contain a predefined volume of a flowable substance.
 5. The device of claim 1, wherein the items may be adhered to multiple sides of the container.
 6. A method of dispensing a predefined number of small items or a predefined volume of a substance at a time, said method comprising the steps of: providing a container where a plurality of items are stored, facilitating separation from the container to allow separation of a predetermined number of individual items, maintaining integrity of overall container after each separation.
 7. The method of claim 6, wherein the facilitation of separation may be accomplished by adhering two or more types of packaging with aligning patterns of separation facilitation.
 8. The method of claim 6, wherein the facilitation of separation may be accomplished using a pattern of separation facilitation on a single type of packaging. 